U.S. patent application number 10/189922 was filed with the patent office on 2003-01-09 for powder fluidizing devices and portable powder-deposition apparatus for coating and spray forming.
Invention is credited to Gabel, Howard, Tapphorn, Ralph M..
Application Number | 20030006250 10/189922 |
Document ID | / |
Family ID | 23175266 |
Filed Date | 2003-01-09 |
United States Patent
Application |
20030006250 |
Kind Code |
A1 |
Tapphorn, Ralph M. ; et
al. |
January 9, 2003 |
Powder fluidizing devices and portable powder-deposition apparatus
for coating and spray forming
Abstract
The invention relates to a powder-fluidizing and feeding device
for use with coating and spray forming nozzles and guns. The device
includes novel provisions for controlling and feeding powder from a
hopper to a vibrating bowl, for heating and vibrating powders in
the hopper to dissipate agglomeration and clumping of the powder,
and for metering powders from a vibrating bowl to the spray nozzles
and guns using a feedback control derived from powder mass loss
rate measurements. The device is particularly useful for feeding
ultra-fine and nanoscale particles, which are difficult to feed
uniformly with the prior art of conventional powder feeders.
Inventors: |
Tapphorn, Ralph M.; (Goleta,
CA) ; Gabel, Howard; (Santa Barbara, CA) |
Correspondence
Address: |
LYON & HARR
Suite 800
300 Esplanade Drive
Oxnard
CA
93030
US
|
Family ID: |
23175266 |
Appl. No.: |
10/189922 |
Filed: |
July 3, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60304147 |
Jul 9, 2001 |
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Current U.S.
Class: |
222/163 |
Current CPC
Class: |
B05B 7/1445 20130101;
Y10S 977/775 20130101; Y10S 977/89 20130101 |
Class at
Publication: |
222/163 |
International
Class: |
B67D 005/64 |
Claims
Wherefore, what is claimed is:
1. A powder fluidizing device, comprising: a vibrating bowl
structure comprising a powder receiving surface, a discharge
conduit, and a feeding channel which provides a spiraling ramp
along which powder moves up from the receiving surface in a lower
part of the vibrating bowl structure to the discharge conduit in a
upper part of the vibrating bowl and out of the powder fluidizing
device through the discharge conduit; a vibrating bowl vibration
mechanism for imparting a rotational oscillation to the vibrating
bowl which causes powder deposited onto the receiving surface to
move along the feeding channel to the discharge conduit; a powder
hopper located above the vibrating bowl, said hopper comprising a
reservoir of powder and a funnel tube extending down into the
vibrating bowl to a point above the receiving surface; and a powder
flow control mechanism for controlling the amount of powder that
flows from the receiving surface to the discharge channel, wherein
said second powder flow control mechanism is a feedback mechanism
which determines the powder mass loss rate from the powder
fluidizing device and adjusts the vibration mechanism to
substantially maintain said loss rate at a prescribed value.
2. The device of claim 1, wherein the powder flow control mechanism
comprises: a mass sensor which outputs a signal indicative of the
weight of the powder in the powder fluidizing device; a computing
device for computing the powder mass loss rate based on the change
in the output signal from mass sensor; and a controller for
controlling the vibrating bowl vibration mechanism so as to adjust
the amount of rotational oscillation imparted to the vibrating
bowl, and so the amount of powder moved to the discharge conduit
and out of the powder fluidizing device, to substantially maintain
said mass loss rate, as computed by the computing device, at a
prescribed value.
3. The device of claim 2, wherein the vibrating bowl vibration
mechanism controller comprises a PID feedback device which
increases the amount of power supplied to the vibrating bowl
vibration mechanism thereby increasing the intensity of the
vibration imparted to the vibration bowl whenever the computed
powder mass loss rate is substantially below said prescribed value,
and which decreases the amount of power supplied to the vibrating
bowl vibration mechanism thereby decreasing the intensity of the
vibration imparted to the vibration bowl whenever the computed
powder mass loss rate is substantially above said prescribed
value.
4. The device of claim 1, wherein the feeding channel of the
vibrating bowl structure is a groove, and wherein the vibrating
bowl structure further comprises gate valve which protrudes into
the groove at a point along its path to limit the amount of powder
which can pass beyond the gate valve to prescribed amount per unit
time.
5. The device of claim 4, wherein the gate valve comprises at least
one rake finger extending down from the gate valve into the powder
allowed to pass by the valve, wherein the rake finger or fingers
break up agglomerated and clumping portions of the powder.
6. The device of claim 1, wherein discharge conduit is fixed to the
vibrating bowl at a proximal end thereof and fixed to an outlet
channel of the powder fluidizing device a the distal end thereof,
and wherein the discharge tube is flexible so as to not interfere
with the rotational oscillation of the vibrating bowl.
7. The device of claim 6, further comprising a pressure housing
surrounding the a powder hopper, vibrating bowl structure, and
associated components thereof, and wherein the pressure chamber is
pressurized with a gas which exits through said outlet channel of
the powder fluidizing device via the discharge conduit, thereby
assisting in the flow of powder through the conduit.
8. The device of claim 1, further comprising a second powder flow
control mechanism for controlling the amount of powder that flows
from the funnel tube to the receiving surface.
9. The device of claim 8, wherein the second powder flow control
mechanism comprises an upper sieve and a lower sieve, wherein the
upper sieve is mounted within the powder hopper so as to meter
powder in said reservoir which overlies the upper sieve onto the
lower sieve which is mounted across an entrance to the funnel tube
so as to meter powder into the funnel tube, and wherein the number,
distribution and aperture size of the holes in each sieve restricts
the amount of powder that can flow through the sieves and enter the
funnel tube from the powder reservoir and are selected to control
the amount of powder that flows into the funnel tube and so onto
the receiving surface of the vibrating bowl.
10. The device of claim 9, wherein the upper sieve comprises two
plates with substantially matching hole patterns which are
rotatable in relation to each other and wherein the size of the
aperture of each sieve hole is adjusted by rotating one of the
plates in relation to the other, thereby controlling the degree to
which the upper sieve restricts the flow of powder from the
reservoir to the lower sieve.
11. The device of claim 9, wherein the lower sieve comprises two
plates with substantially matching hole patterns which are
rotatable in relation to each other and wherein the size of the
aperture of each sieve hole is adjusted by rotating one of the
plates in relation to the other, thereby controlling the degree to
which the lower sieve restricts the flow of powder into the funnel
tube.
12. The device of claim 8, wherein the second powder flow control
mechanism further comprises a powder hopper vibration mechanism
which vibrates the powder hopper so as to facilitate the flow of
powder through the sieves.
13. The device of claim 12, wherein the second powder flow control
mechanism further comprises: a level sensor that senses the amount
of powder residing on the receiving surface of the vibrating bowl
and outputs a signal indicative of that amount; and a powder hopper
vibration mechanism controller which controls the amount of
vibration imparted to the powder hopper by the hopper vibration
mechanism so as to control the amount of powder deposited onto the
receiving surface of the vibrating bowl, as indicated by the level
sensor, to approximately a prescribed amount.
14. The device of claim 13, wherein the level sensor comprises: a
flexible vane that deflects in proportion to the amount of powder
residing on the receiving surface of the vibrating bowl; and a
deflection sensor which detects the amount of deflection exhibited
by the flexible vane and outputs a signal indicative thereof.
15. The device of claim 14, wherein the powder hopper vibration
mechanism controller comprises a switch which turns the powder
hopper vibration mechanism on when the deflection sensor indicates
the deflection of the flexible vane is small enough to indicate an
inadequate amount of powder exists on the receiving surface of the
vibrating bowl, and which turns the powder hopper vibration
mechanism off when the deflection sensor indicates the deflection
of the flexible vane is large enough to indicate that an adequate
amount of powder exists on the receiving surface of the vibrating
bowl.
16. The device of claim 14, wherein the powder hopper vibration
mechanism controller comprises a PID feedback device which varies
the amount of power supplied to the powder hopper vibration
mechanism in proportion to the deflection of the flexible vane as
detected by the deflection sensor.
17. The device of claim 14, wherein the funnel tube comprises a
cutout notch at its distal end adjacent the receiving surface and
facing the flexible vane to preferentially accumulate powder in
front of the vane.
18. A powder fluidizing device, comprising: a vibrating bowl
structure comprising a powder receiving surface, a discharge
conduit, and a feeding channel which provides a spiraling ramp
along which powder moves up from the receiving surface in a lower
part of the vibrating bowl structure to the discharge conduit in a
upper part of the vibrating bowl and out of the powder fluidizing
device through the discharge conduit; a vibrating bowl vibration
mechanism for imparting a rotational oscillation to the vibrating
bowl which causes powder deposited onto the receiving surface to
move along the feeding channel to the discharge conduit; a powder
hopper located above the vibrating bowl, said hopper comprising a
reservoir of powder overlying at least one sieve mounted within the
powder hopper so as to meter powder in said reservoir to a funnel
tube extending down into the vibrating bowl to a point above the
receiving surface; and a powder flow control mechanism for
controlling the amount of powder that flows from the funnel tube to
the receiving surface, wherein said first powder flow control
mechanism comprises a powder hopper vibration mechanism which
vibrates the powder hopper so as to facilitate the flow of powder
through the sieve or sieves.
19. The device of claim 18, wherein the powder flow control
mechanism further comprises: a sensor that senses the amount of
powder residing on the receiving surface of the vibrating bowl and
outputs a signal indicative of that amount; and a powder hopper
vibration mechanism controller which controls the amount of
vibration imparted to the powder hopper by the hopper vibration
mechanism so as to control the amount of powder deposited onto the
receiving surface of the vibrating bowl, as indicated by the
sensor, to approximately a prescribed amount.
20. A powder fluidizing device, comprising: a vibrating bowl
structure comprising a powder receiving surface, a discharge
conduit, and a feeding channel which provides a spiraling ramp
along which powder moves up from the receiving surface in a lower
part of the vibrating bowl structure to the discharge conduit in a
upper part of the vibrating bowl and out of the powder fluidizing
device through the discharge conduit; a vibrating bowl vibration
mechanism for imparting a rotational oscillation to the vibrating
bowl which causes powder deposited onto the receiving surface to
move along the feeding channel to the discharge conduit; a powder
hopper located above the vibrating bowl, said hopper comprising a
reservoir of powder and a funnel tube extending down into the
vibrating bowl to a point above the receiving surface; a first
powder flow control mechanism for controlling the amount of powder
that flows from the funnel tube to the receiving surface; a second
powder flow control mechanism for controlling the amount of powder
that flows from the receiving surface to the discharge channel; and
a heating unit which heats the powder in the powder hopper
reservoir to a temperature high enough to dissipate agglomeration
and clumping of the powder.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of a previously filed
provisional patent application Serial No. 60/304,147, filed on Jul.
9, 2001.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to various powder-fluidizing
and feeding devices for use with coating and spray forming nozzles
and guns. The invention discloses new techniques for feeding
ultra-fine and nanoscale particles, which are difficult to feed
uniformly with the prior art of conventional powder feeders.
[0004] 2. Background Art
[0005] The powder feeder disclosed in U.S. Pat. No. 3,618,828
issued to Schinella uses a vibrating structure to move powder from
a receiving surface along a feeding surface to a discharge channel.
The primary benefit of this type of powder feeder over prior art is
uniform feeding of the powder feedstock without inducing pulsation
caused by turbulence in the carrier gas flow. In addition, this
type of feeder permits metering of the powder independent of the
carrier gas flow rate and properties. The patent further describes
the use of a hopper with an outlet channel and a hemispherical cup
for metering powder (under the influence of gravity) onto the
feeding surface through a smaller port than the outlet channel. The
vibratory drive imparts rotary motion to the feeding surface for
moving the powder in an outward spiral path along the feeding
surface from the receiving surface to the discharge channel. The
spacing between the port of the hemispherical cup and the receiving
surface is less than the flow control dimension of the port. The
feeder structure and hopper of U.S. Pat. No. 3,618,828 is disposed
in a chamber for entraining the powder in a carrier gas fed through
the discharge channel.
[0006] The primary limitation of the powder feeder disclosed in
U.S. Pat. No. 3,618,828 is that uniformity of powder metering is
highly dependent on the particle size and agglomeration
characteristics of the powder. This is particularly true for
ultra-fine and nanoscale powders with particle diameters of less
than 10 micrometers. For highly agglomerating powders, the
hemispherical cup becomes plugged preventing feed from the hopper
to the receiving surface. For smooth flowing powders, there is a
tendency under the influence of gravity to dump large quantities of
powder in an uncontrolled manner onto the receiving surface.
Particularly, once powder flow is initiated, uncontrollable feed
frequently occurs through all ports and openings in the
hemispherical cup resulting in an overflow condition onto the
receiving surface.
[0007] Feeding of nanometer size particles is considerably more
difficult because of the agglomerating aspects ascribed to Van der
Waals forces (Handbook of Physics and Chemistry, 68 edition, CRC
Press, E-67) acting between the particles. Prior art for dispensing
and dispersing nanometer size particles has primarily been limited
to colloidal suspensions.
[0008] Conventional powder feeding units such as that disclosed in
U.S. Pat. No. 4,808,042 to Muehlberger, et al., U.S. Pat. No.
4,740,112 to Muehlberger, et al., U.S. Pat. No. 4,726,715 to Steen
et al., U.S. Pat. No. 4,4,561,808 to Spaulding, et al. or in U.S.
Pat. No. 4,3,565,296 to Brush, et al., all have difficulty
uniformly feeding ultra fine powder. These feeders tend to induce
pulsation at low feed rates due to agglomeration or are not able to
inject powders into high-pressure guns or nozzles.
SUMMARY
[0009] The present invention relates to various powder-fluidizing
and feeding devices for use with coating and spray forming nozzles
and guns. The invention discloses new techniques for feeding
ultra-fine and nanoscale particles, which are difficult to feed
uniformly with the prior art of conventional powder feeders. The
present invention allows powders to be fed into conventional
coating and spray forming nozzles and guns, but more importantly
into choked supersonic nozzles such as those disclosed in U.S. Pat.
No. 5,795,626 issued to Gabel and Tapphorn, U.S. Pat. No. 6,074,135
issued to Tapphorn and Gabel, and friction compensated sonic
nozzles disclosed in U.S. patent application Ser. No. 10/116,812
filed by Tapphorn and Gabel on Apr. 5, 2002. These choked nozzles
require a high nozzle-inlet pressure which precludes uniform
injection of powders using conventional powder feeders. The
attribute of the invented powder-fluidizing device that permits
injection into high inlet pressure nozzles is powder feeding that
is independent of the gas mass flow characteristics. Thus, the
powder fluidizing gas can be maintained at a sufficient pressure
and flow rate to inject into a nearly isostatic nozzle inlet
pressure, while powder is independently metered and entrained into
the powder fluidizing gas.
[0010] Improvements to the powder-feeding concept, disclosed in
U.S. Pat. No. 3,618,828, include sieve plates mounted within a
hopper for precise metering of powder into a vibrating bowl. Powder
is metered through the sieve plates by a hopper vibrator that is
controlled by a level sensor mounted in the vibrating bowl. Other
means for metering the powder through conventional pinch, iris, and
cone valves are included as a means of metering powders from the
hopper into the vibrating bowl. A funnel tube at the base of the
hopper extends down into the vibrating bowl to direct the powder
agitated through the sieve plates into the vibrating bowl. The
funnel tube restricts powder fuming to a small confined volume
within the funnel tube as the powder drops to the vibrating bowl
surface. This technique eliminates any coupling between the
vibrating bowl and the base structure that may dampen or perturb
the vibration intensity during operation. Other improvements to the
prior art include a means for heating and vibrating powders in the
hopper to dissipate agglomeration and clumping of the powder, and
methods for improving the precision and accuracy of metering
powders from a vibrating bowl through a spiral-ramp groove and
feedback control derived from mass loss or particle feed rate
measurements.
[0011] This invention also relates to several embodiments of
portable powder deposition devices for deposition and consolidation
of powder particles using friction compensated sonic nozzles such
as those disclosed in the aforementioned U.S. patent application
Ser. No. 10/116,812 filed by Tapphorn and Gabel on Apr. 5, 2002 or
supersonic nozzles as disclosed in U.S. Pat. No. 5,795,626 issued
to Gabel and Tapphorn, and U.S. Pat. No. 6,074,135 issued to
Tapphorn and Gabel.
DESCRIPTION OF THE DRAWINGS
[0012] The specific features, aspects, and advantages of the
present invention will become better understood with regard to the
following description, appended claims, and accompanying drawings
where:
[0013] FIG. 1. Cross-section view of the powder-fluidizing device
with specific improvements over the prior art for controlling and
measuring powder feed uniformity and rates including sieve plates
used to control and meter powder from the hopper to the vibrating
bowl.
[0014] FIG. 2. Cross-section and top plan view of the vibrating
bowl with a spiral-ramp groove running from the central reservoir
region to the discharge outlet for the bowl. Figure also depicts a
gate valve installed in the vibrating bowl to fine-tune the
metering of powder through the gate valve aperture defined by the
height above the base of the spiral-ramp groove and the width of
the groove.
[0015] FIG. 3. Shows a plan view of typical upper and lower sieve
plates used to control and meter powder from the hopper to the
vibrating bowl.
[0016] FIG. 4. Cross-section view of the powder-fluidizing device
with specific improvements over the prior art for controlling and
measuring powder feed uniformity and rates including a an iris
valve used to control and meter powder from the hopper to the
vibrating bowl.
[0017] FIG. 5. Cross-section view of an iris valve used as an
alternative embodiment to control and meter powder from the hopper
to the vibrating bowl.
[0018] FIG. 6. Shows a plan view of a vibrating bowl powder level
sensor using a flexible metal vane in combination with a proximity
switch.
[0019] FIG. 7. Shows an isometric view of the vibrating bowl powder
level sensor with flexible metal vane in relationship to exit of
the hopper funnel tube that ensures accumulation of powder in front
of the flexible metal vane so as to induce deflection thereof.
[0020] FIG. 8. Shows a block diagram of a mass sensor used to
measure mass loss rates and a PID controller to adjust the AC power
to the electromagnets of the vibrating bowl in proportion to a
preset feed rate. Figure also shows the use of flexible metal vane
proximity switch to control the AC power to the hopper vibrator for
agitating the powder down through the upper and lower sieve
plates.
[0021] FIG. 9. Block diagram of first embodiment for a portable
powder deposition apparatus using the powder-fluidizing device
shown in cross-section. Figure also shows the use of an orifice
restrictor in combination with a friction compensated sonic nozzle
for modifying and controlling feed rates to the nozzle.
[0022] FIG. 10. Block diagram of second embodiment for a portable
powder deposition apparatus using a technique for fluidizing
powders above the level of the bulk powder. Figure also shows the
use of an orifice restrictor in combination with a friction
compensated sonic nozzle for modifying and controlling feed rates
to the nozzle.
[0023] FIG. 11. Block diagram of a third embodiment for a portable
powder deposition apparatus using a powder fluidizing device for
microgravity operations in which the particle flow sensor is used
to control the feeding of powder via adjustment of carrier gas flow
through the powder fluidizing device relative to process line
carrier gas flow. Figure also shows the use of an orifice
restrictor in combination with a friction compensated sonic nozzle
for modifying and controlling feed rates to the nozzle.
[0024] FIG. 12. Schematic diagram of a powder fluidizing device for
fluidizing powders within a drop tube in which carrier gas is used
to entrain powder during gravity flow of the powder through an
upper and lower sieve plate or pinch valve that is metered by a
vibrator attached to the hopper.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] In the following description of the preferred embodiments of
the present invention, reference is made to the accompanying
drawings, which form a part hereof, and in which is shown by way of
illustration specific embodiments, which the invention may be
practiced. It is understood that other embodiments may be utilized
and structural changes may be made without departing form the scope
of the present invention.
[0026] In general, the present invention relates to various
powder-fluidizing and feeding devices for use with coating and
spray forming nozzles and guns. The invention discloses new
techniques for feeding ultra-fine and nanoscale particles, which
are difficult to feed uniformly with the prior art of conventional
powder feeders. Improvements to the powder-feeding concept of U.S.
Pat. No. 3,618,828 issued to Schinella are disclosed in this
invention. These improvements include apparatus and methods for
controlling and feeding powder from a hopper to a vibrating bowl,
for heating and vibrating powders in the hopper to dissipate
agglomeration and clumping of the powder, and for improving the
precision and accuracy of metering powders from a vibrating bowl
through feedback control derived from mass loss or particle feed
rate measurements.
[0027] This invention also relates to portable powder deposition
devices for deposition and consolidation of powder particles using
friction compensated sonic nozzles such as those disclosed in the
aforementioned U.S. patent application Ser. No. 10/116,812 filed by
Tapphorn and Gabel on Apr. 5, 2002.
[0028] FIG. 1 show the basic embodiment of the powder-fluidizing
device 1 used in this invention. The hopper 2 is isolation mounted
to plate 3 which is mounted through a first structural support
bracket 4 that is detachable from a second structural support
bracket 5 which mounts to the pressure housing base 6 via the mass
sensor 7. Detachment of first structural support bracket 4 from the
second structural support bracket 5 permits the hopper 2 to be
removed from the vibrating bowl 8 for cleaning and servicing of
components. A upper sieve plate 9 mounted within hopper 2 meters
powder 10 onto a lower sieve plate 11 for more precise metering of
powder 10 into funnel tube 12. Funnel tube 12 at the base of the
hopper 2 extends down into the vibrating bowl 8 to direct the
powder 10 agitated through the sieve plates 9 and 10 into the
vibrating bowl 8. The funnel tube 12 restricts the powder 10 fuming
to a small confined volume within the powder-fluidizing device 1 as
the powder 10 drops to the vibrating bowl 8 surface. This technique
also eliminates any coupling between the vibrating bowl 8 and the
funnel tube 12 that may dampen or perturb the vibration intensity
during operation.
[0029] The invention includes another improvement over the prior
art of U.S. Pat. No. 3,618,828 to dissipate agglomeration and
clumping of the powder 10 by heating the hopper 2 and stored powder
10 to a temperature in the range of 100-250.degree. F. using a band
heater 13 attached to the structural base 14 of the hopper 2. This
technique permits any moisture or other volatile contamination to
be driven from the powder 10 and removed with the carrier gas 15.
In addition, the electrostatic agglomeration forces are dissipated
at elevated temperatures, which tend to improve the powder flow
characteristics.
[0030] This invention includes several techniques for level sensing
of powder 10 in the reservoir of the vibrating bowl 8. One method
uses a flexible metal vane 16 (type of float) that deflects in
proportion to the level of powder 10 in the vibrating bowl 8 as
said powder 10 is rotated in a spiraling manner to toward the
discharge outlet 17. A conventional proximity switch 18 based on
eddy current, magnetic, capacitance, or optical measurement detects
deflection of the flexible metal vane 16 to switch the AC power to
the hopper vibrator 19 or to proportionally control the vibration
intensity. The exit of the funnel tube 12 is designed with a cutout
notch 20 to preferentially accumulate powder 10 in front of the
flexible metal vane 16 so as to insure deflection thereof. Other
sensing techniques including optical interrupter switches, optical
ranging devices, eddy current, magnetic, an capacitance transducers
are included as alternative embodiments of a powder level
sensor.
[0031] Referring now to FIGS. 1 and 2, the vibrating bowl 8 of this
invention is further improved with a spiral-ramp groove 21 that
spirals up a ramp from the bottom of the vibrating bowl 8 to the
discharge tube 17. The width and cross-section shape of the
spiral-ramp groove 21 is designed to translate and meter the powder
10 up the spiral-ramp groove 21 at a flow rate in proportion to the
applied rotary vibration intensity. The vibrator mechanism 22 uses
conventional electromagnetic poles to rotationally drive and
oscillate a bowl mounting plate 23 such as the technique disclosed
in U.S. Pat. No. 3,618,828 or other commercial parts feeding and
conveying vibrators such as those manufactured by FMC Corp., Homer
City, Pa. The angle of the spiral-ramp groove 21, relative to the
horizontal plane, is adjusted to provide a minimum of one
revolution in which to raise the powder 10 above a reservoir level
as determined by the flexible metal vane 16 or other level sensing
device. Typically the cross-section shape of the spiral-ramp groove
21 is hemispherical at the base of channel, but other shapes
including chamber radii rectangular or square channels are
included. The depth of the spiral-ramp groove 21 is yet another
variable for controlling the metering of the powder 10 from the
reservoir to the discharge outlet 17 of the vibrating bowl 8. A
gate valve 24 (dam or scraper) can also be inserted into the
spiral-ramp groove 21 at various depths and locations to fine-tune
the metering of the powder 10 through the gate-valve 24 apertures
as the powder 10 is rotationally translated up the spiral-ramp
groove 21. It is also advantageous to permit the gate valve 24 to
vibrate in order to prevent agglomeration and clumping of the
powder as it translates through the aperture. Rake fingers 25, for
example a single wire or plurality of wires, mounted in the center
of the spiral-ramp groove 21 can also be used to break up
agglomerating and clumping powder 10 to provide a more uniform
powder flow rate.
[0032] The discharge outlet 17 from the vibrating bowl 8 has an
additional improvement over the prior art of U.S. Pat. No.
3,618,828, wherein the discharge outlet 17 extends down through the
vibrator mechanism 22 via a flexible polymeric tube 26 to mitigate
vibration coupling between the vibrating bowl mounting plate 23 and
the base 27 of the vibrator mechanism. The distal end of said
discharge tube 17 partially protrudes into an outlet funnel 28 for
connecting the powder-fluidizing device 1 to an application gun or
nozzle via a high-pressure flexible hose or tube. This feature
permits the carrier gas 15 to flow independent of the powder 10
dispensing over a wide range of gas flow rates and pressures, while
entraining and mixing the powder 10 into the carrier gas 15 as the
mixture is discharged from the powder fluidizing device 1. The
outlet funnel 28 internal diameter and taper is matched to the
internal diameter of the flexible hose or tube to maintain the
powder 10 flow in the carrier gas 15 at velocities sufficiently
high to prevent settling and agglomeration of the powder within the
hose.
[0033] Finally an additional improvement of this invention over the
prior art is the addition of a mass sensor 7 (e.g., electronic load
cell or optical load cell) mounted between the pressure housing
base 6 and the second structural support bracket 5 that permits a
measurement of the mass of powder 10 remaining in the hopper 2. The
signal from the mass sensor 7 also permits the powder flow rate to
be computed as the average mass loss rate of powder flowing from
the powder-fluidizing device 1. Both of these measurements are
independent of the gas mass flow rate, which permits the powder
flow rates to be measured and controlled to a set point via a
Proportional Integral Derivative (PID) feedback controller to the
power supply for the bowl vibrator. These PID controllers can be
implemented with conventional analog electronic devices or with
software algorithms such as those supplied by National Instruments
in LabView.TM. virtual instrumentation software.
[0034] The carrier gas 15 pressurizes the powder-fluidizing device
1 cavity enclosed by the pressure housing 29 and the
pressure-housing base 6 via a pipe coupling clamp 30 sealed by a
rubber seal 31. The cap 32 installed in pressure housing 29
provides the means for venting pressurized carrier gas 15 through
vent valve 33 and for refilling the hopper 2 using a conventional
funnel inserted into port 34.
[0035] It should be pointed out that a plurality of powder
fluidizing devices 1 disclosed in this invention could be used to
mix and entrain various powders at selected concentrations into a
common manifold that is connected to the gun of a nozzle
applicator.
[0036] A particular combination of upper sieve plate 9 and lower
sieve plate 11 is shown in FIG. 3 with a plurality of holes 35 and
36 tuned to dispense powder under conditions suitable for flow
characteristics of the powder 10 and to meet the flow rate demand
for the specific application. The number and distribution of holes
in the upper sieve plate 9 and lower sieve plate 11, and the
hole-size, permit tuning of the sieve plates (9 and 11) for a
particular powder 10. Variable hole size in the upper sieve plate 9
and lower sieve plate 11 can also be accomplished by coupling a
dual plate together with a similar hole pattern and rotating one
plate in reference to the other in order to occult the hole area in
a variable manner. Referring again to FIG. 1, a mechanical or
electrical driven vibrator 19 attached to plate 3 is used to shake
the powder down through the sieve plates (9 and 11) on demand from
a flexible metal vane switch 16. The hopper 2 is vibration isolated
from the vibrating bowl 8 through the first structural support
bracket 4 and the second structural support bracket 5 of the
powder-fluidizing device 1 with shock absorbing mounts. A signal
from the flexible metal vane switch 16 is used to control (PID
feedback or on/off switching) the hopper vibrator 19 so as to meter
powder 10 at an acceptable rate.
[0037] Alternatively, the metering of powder 10 into the vibrating
bowl 8 can be accomplished by using a variable orifice iris valve
37 at the outlet of the hopper 2 as shown in FIG. 4. A rotary
actuator as shown in FIG. 5 can remotely control iris valves 37
such as those sold by FMC INC. or Mucon, Inc. A linear motor, lead
screw assembly, solenoid, pneumatic cylinder, or hydraulic cylinder
can be used to drive the rotary actuator for controlling the
variable orifice area of the valves. Other types of pinch valves
such as the AirFlex.RTM. device manufactured by RF Technologies,
Inc. or the flex tube device disclosed in U.S. Pat. No. 6,056,260
issued to Stewart and Day can also be used. Conventional cone
valves used in hopper for bulk feeding of powders could also be
used to meter powder from the hopper to the vibrating bowl. Again,
a signal from the flexible metal vane 16 switch or other bowl level
sensor is used to control (PID feedback or on/off switching) the
hopper vibrator 19 so as to meter powder 10 at an acceptable
rate.
[0038] A detailed drawing of the powder level, sensor in the
vibration bowl 8 is shown in FIG. 6. This particular embodiment
uses an Eddy current proximity switch 18 that detects the
displacement of the flexible metal vane 16 as the powder 10 level
decreases from level 38 to level 39. Referring to FIGS. 1 and 6,
the hopper vibrator 19 is turn on by the proximity switch 18 when
the powder 10 is at level 39 which begins to meter powder from the
hopper 2 through the upper sieve plate 9 and lower sieve plate 11
down through the funnel tube 12 until the powder level 38 in FIG. 6
is reached. Once the powder level 38 is attained the proximity
switch 18 turns the hopper vibrator 19 off and the cycle is
repeated to keep the powder 10 in the vibrating bowl 8 at nearly a
constant level. Other types of sensors including optical
interrupter switches, optical ranging devices, magnetic, or
capacitance transducers could be used to detect the displacement of
the flexible metal vane 16 or detect the powder levels 38 and 39 in
the vibrating bowl. In many cases, these sensors could provide a
continuous signal proportional to the difference between level 38
and level 39 which would operate the hopper vibrator 19 intensity
in proportion to the powder 10 level through PID feedback. This
approach could be used to improve the precision of the powder 10
metering from the hopper 2 to the vibrating bowl 8 by providing a
more constant level of powder 10 between level 38 and 39.
[0039] FIG. 7 shows a detail drawing of the cutout notch 20 in the
funnel tube 12 that is used to accumulated powder 10 in front of
the flexible metal vane 16 switch. Rotational vibrating of the
vibrating bowl 8 shown in FIGS. 1 and 2 induces rotation of the
powder 10 in a counterclockwise direction as depicted in FIG.
7.
[0040] FIG. 8 is schematic of the control system used to drive the
powder-fluidizing device 1. The AC electrical power 40 to the
hopper vibrator 19 is switched on and off by the proximity switch
18 associated with the flexible metal vane 16 used to control the
level of powder 10 in the vibrating bowl 8. The powder 10 is
agitated down through upper sieve plate 9 and lower sieve plate 11
whenever AC electrical power 40 is applied to the hopper vibrator
19. FIG. 8 also shows a computer controlled PID feedback system 41
for controlling the AC power controller 42, which determines the
current delivered to the electromagnets in the vibration mechanism
22 of the vibrating bowl 8. The powder feed rate derived from the
mass sensor 7 is regulated to a desired set point by the PID
feedback system 41. Note other transducers including coriolis mass
flow, turbidity, and thermal loss could be used to measure the
powder feed rate in this embodiment.
[0041] Although many different particle-spraying processes can be
used with the powder fluidizing apparatus and process disclosed in
this invention, one specific example is illustrated to demonstrate
the capabilities. The powder-fluidizing device disclosed in this
invention is notably designed to feed ultra-fine or nanoscale
powders into choked nozzles that operate at inlet gas pressures
well in excess of atmospheric pressure. The friction compensated
sonic nozzles disclosed in the aforementioned U.S. patent
application Ser. No. 10/116,812 filed by Tapphorn and Gabel on Apr.
5, 2002 represent a particular type of nozzle that can be used with
the powder-fluidizing device. In tests conducted with the powder
fluidizing apparatus, aluminum powder having an average particle
size of 20 micrometers with an upper limit of 45, micrometers was
blended 50% by weight with chromium powder (<45 micrometers) and
fed into the friction compensated sonic nozzles as per the
specifications disclosed in the aforementioned U.S. patent
application Ser. No. 10/116,812 filed by Tapphorn and Gabel on Apr.
5, 2002. The powder flow rate for these tests indicated a mass flow
rate within .+-.1% of the set point (30 gm/min) with a .+-.1%
precision over sampling periods of 90 seconds as determined by a
mass loss measurements using the internal mass sensor 7. Other
choked nozzles, including supersonic nozzles as disclosed in U.S.
Pat. No. 5,795,626 issued to Gabel and Tapphorn and U.S. Pat. No.
6,074,135 issued to Tapphorn and Gabel can also be used with the
powder-fluidizing device for uniformly spraying ultra-fine or
nanoscale powders independent of the carrier gas flow rates.
[0042] A first embodiment of a portable powder deposition apparatus
that uses the powder-fluidizing device 1 is shown schematically in
FIG. 9. The first embodiment of the portable powder deposition
apparatus consists of using a nozzle 43 such as a friction
compensated sonic nozzle disclosed in the aforementioned U.S.
patent application Ser. No. 10/116,812 filed by Tapphorn and Gabel
on Apr. 5, 2002 in combination with the powder-fluidizing device 1
of this invention. A portable gas source 44 consisting of helium,
nitrogen, argon or mixture thereof stored in small portable
cylinders is used with the portable-powder deposition apparatus.
For this particular embodiment, carrier gas 15 is injected into
powder-fluidizing device 1 to entrain powder 10 particles prior to
injection into the nozzle 43. Adjusting a conventional regulator 45
sets the operating pressure, and the carrier gas 15 with entrained
powder 10 is injected into the handheld nozzle via flow control
valve 46. Optionally, an orifice-restrictor 47 such as a second
friction compensated sonic nozzle disclosed in the aforementioned
U.S. patent application Ser. No. 10/116,812 filed by Tapphorn and
Gabel on Apr. 5, 2002 connected in series with the nozzle 43 is
used to additionally modify and control the flow rate of the powder
10 particles entrained in the carrier gas 15. The orifice diameter
is sized to yield the desired result, but typically is comparable
to the throat dimensions of the nozzle 43. This first embodiment of
the portable powder deposition apparatus is typically used for
depositing metallic spot coatings, touchup coatings, or in-situ
repairs of components or structures by spray forming. Conventional
sand blasting cabinet or other enclosure evacuated through a
conventional dust collector filter (not shown explicitly in FIG. 9)
can be used to environmentally contain the excess powder released
during spray operations and to vent the inert gases to the
atmosphere.
[0043] A second embodiment of the portable powder deposition
apparatus shown in FIG. 10 includes using a nozzle 43 such as a
friction compensated sonic nozzle disclosed in the aforementioned
U.S. patent application Ser. No. 10/116,812 filed by Tapphorn and
Gabel on Apr. 5, 2002 in combination with an alternative embodiment
of a powder-fluidizing chamber 49 that uses a movable fluidizing
port 48 mounted within the powder-fluidizing chamber 49 for
dispensing small quantities of powder 10 to the nozzle 43 for
touching up coated areas or spray forming repairs. This alternative
embodiment of the powder-fluidizing chamber 49 was also disclosed
in the aforementioned U.S. patent application Ser. No. 10/116,812
filed by Tapphorn and Gabel on Apr. 5, 2002 as a method of
fluidizing powders above the level of the powder. A portable gas
source 44 consisting of helium, nitrogen, argon or mixture thereof
stored in small portable cylinders is used with this second
embodiment of the portable powder deposition apparatus. Optionally,
an orifice-restrictor 47 such as a second friction compensated
sonic nozzle disclosed in the aforementioned U.S. patent
application Ser. No. 10/116,812 filed by Tapphorn and Gabel on Apr.
5, 2002 connected in series with the hand held nozzle 43 is used to
additionally modify and control the flow rate of the powder
particles entrained in the carrier gas 15. This second embodiment
of the portable powder deposition apparatus is also typically used
for depositing metallic spot coatings, touchup coatings, or in-situ
repairs of components or structures by spray forming. A
conventional sand blasting cabinet or other enclosure evacuated
through a conventional dust collector filter (not shown explicitly
in FIG. 10) can be used to environmentally contain the excess
powder released during spray operations and to vent the inert gases
to the atmosphere.
[0044] Referring to schematic diagram of FIG. 11, a third
embodiment of the portable powder deposition apparatus for use in
microgravity consists of using a nozzle 43 such as friction
compensated sonic nozzle disclosed in the aforementioned U.S.
patent application Ser. No. 10/116,812 filed by Tapphorn and Gabel
on Apr. 5, 2002 in combination with the powder-fluidizing chamber
49 describe in FIG. 10. In microgravity, the entire powder 10 load
in the powder-fluidizing chamber 49 will be dispersed within the
carrier gas 15 rather than resting on the bottom of the
powder-fluidizing chamber 49. Electrostatic forces will still be
present which can lead to local agglomerations, but these forces
can be successfully dissipated in most powders by heating the
powder to a temperature of 340 K. An orifice restrictor 47 in the
outlet line of the powder fluidizing chamber 49 is used to control
the volumetric admixture of the carrier gas 15 with entrained
powder particles injected into a manifold 50 located at the inlet
to the nozzle 43 comprising the friction compensated sonic nozzle.
A remotely controlled metering valve 51 adjusts the carrier gas 15
flow rate through the powder-fluidizing chamber 49 in proportion to
a required or preset powder flow rate. This technique requires a
particle flow sensor 52 for measuring the particle flow rates of
the powder independent of carrier gas 15 flow rates. A conventional
turbidity sensor is the most reliable technique for measuring
powder particle flow rates in microgravity environments, with
negligible sensitivity to the carrier gas 15 flow rate. Turbidity
sensors can be constructed using light emitting diodes and
photodiodes mounted with diamond-coated windows within a flow
sensor housing to measure light attenuation as the powder occults
the beam path. A PID controller 54 is used to adjust the carrier
gas 15 flow rate for a preset particle flow rate as calibrated in
accordance with the turbidity sensor signal. Powder entrain in the
carrier gas 15 is then mixed with additional carrier gas 53 at the
manifold 50 prior to injection into the nozzle 43.
[0045] A schematic diagram of another embodiment for a
powder-fluidizing device that uses a drop tube 55 is shown in FIG.
12. Powder 10 is entrained in the carrier gas 15 during gravity
flow of the powder 10 that is metered through the upper sieve plate
9 and lower sieve plate 11 by a hopper vibrator 19 attached to
plate 3 of the hopper 2. The drop tube 55 of the powder-fluidizing
device is used to create a powder-dispersed condition, while
simultaneously entraining the powder 10 in the carrier gas 15 at a
specific concentration prior to exiting the pressure housing 29
through outlet 56. To achieve heavy concentrations of powder 10
dispersed in the drop tube 55, it is necessary to introduce a
conventional pinch or iris valve in the outlet of the hopper, which
can be remotely activated. The powder recovery chamber 57 at the
base of the drop tube 55 is used to collect excess powder 10 that
is not entrained into the carrier gas 15.
[0046] The types of powder particles that can be deposited or
consolidated using the apparatus and process of this invention are
selected from a group but are not limited to powders consisting of
metals, alloys, low temperature alloys, high temperature alloys,
superalloys, braze fillers, metal matrix composites, nonmetals,
ceramics, polymers, and mixtures thereof. Indium or tin-based
solders and silicon based aluminum alloys (e.g., 4043, 4045, or
4047) are examples of low temperature alloys that can be deposited
and consolidated in the solid-state for coatings, spray forming,
and joining of various materials using the apparatus and process of
this invention. High temperature alloys include, but are not
limited to NF616 (9Cr-2W-Mo-V-Nb-N), SAVE25 (23Cr-18Ni-Nb-CuN),
Thermie (25Cr-20Co-2Ti-2Nb-V-Al), and NF12
(11Cr-2.6W-2.5Co-V-Nb-N). Superalloys include nickel, iron-nickel,
and cobalt-based alloys disclosed on page 16-5 of Metals Handbook,
Desk Edition 1985, (American Society for Metals, Metals Park, Ohio
44073. Powder particles coated with another metal such as nickel
and cobalt coated tungsten powders are also included as a special
type of composite powder that can be used with apparatus and
process of the invention.
[0047] The preferred powder particle size for the apparatus and
process of this invention is generally a broad distribution with an
upper limit of -325 mesh (<45 micrometers), but powder particles
sizes in excess of 325 mesh (45 micrometers) are frequently
selected as strengthening agents for co-deposition with a matrix
material for forming metal matrix composites. Powder particle sizes
in the nanoscale regime can also be deposited and consolidated with
apparatus and process of this invention.
[0048] The types of substrate materials that can be coated or used
for deposition and consolidation surfaces with the apparatus and
process of the invention are selected from a group but are not
limited to materials consisting of metals, alloys, low temperature
alloys, high temperature alloys, superalloys, metal matrix
composites, nonmetals, ceramics, polymers, and mixtures
thereof.
[0049] Various gases can be used with the present invention and are
selected from a group comprising air, argon, carbon tetrafluoride,
carbonyl fluoride, helium, hydrogen, methane, nitrogen, oxygen,
silane, steam, sulfur hexaflouride, or mixtures thereof.
[0050] Methods for depositing nonmetallic powders selected from a
group comprising polymers, ceramics, or glasses using the apparatus
and process of this invention are also disclosed. In particular
powders of high-density polyethylene or polytetrafluoroeythylene
(Teflon.TM.) can be applied as thin coatings. Although not intended
to accommodate the high temperature depositions required for
melting ceramic and glass powders, these materials can be
co-deposited as an ex-situ strengthening agent (powder form) in
metallic or nonmetallic matrix materials.
[0051] The technical advantage of using the process described in
this invention over existing spray coating technologies (e.g., gas
thermal spray, plasma arc-spray, wire-arc-spray, and high velocity
oxygen-fuel spray) is that it produces low-porosity metal
depositions with no surface pretreatment, excellent adhesion, no
significant in-situ oxidation, and no coating-process induced
thermal distortion of the substrate.
[0052] Finally, the apparatus and process of this invention permits
co-deposition of powders to functionally form in-situ and ex-situ
composites. In one example, a metallic powder (e.g., aluminum) is
co-deposited with an ex-situ strengthening agent selected from a
group comprising silicon, carbide, boron carbide, alumina, tungsten
carbide, or mixtures thereof to form a particle reinforced metal
matrix composite that has homogeneous dispersion of the
strengthening agent. In another example the invention permits the
co-deposition of metallic powders into a consolidated composite
that is subsequently transformed (final heat treatment) into an
in-situ particle reinforced metal matrix composite after finish
machining. A variation of this example permits the co-deposition of
metallic powders with other metallic or nonmetallic powder mixtures
to tailor coatings or spray formed materials with unique
properties. For instance, by co-depositing mixtures of aluminum and
chromium powders (equal parts by weight), an electrically
conductive strip can be applied to steel that has a tailored
electrical resistivity (i.e., typically 72 .mu..OMEGA.-cm),
excellent corrosion resistance (20 years in salt water immersion at
70.degree. F.) and an excellent adhesion strength on steel.
[0053] The invention also includes consolidation of functionally
graded materials in which the properties of the deposition (e.g.
thermal expansion) are functionally graded in discrete or step-wise
layers as well as continuously graded. Continuous grading of
functionally graded materials is accomplished by co-depositing
powder mixtures in which the concentration of the admixture is
varied as a function of coating thickness.
[0054] A combination of functionally formed and functionally graded
materials is included in the invention. An example of this
embodiment includes encapsulation of an inner core of material
(e.g. metallic alloy, metallic foam, ceramic or composite) with a
monolithic layer, functionally graded layer of materials,
functionally formed in-situ composite or functionally formed
ex-situ composites to tailor specific properties of the finished
part or component.
[0055] Although the scope of the apparatus and process of this
invention has been described in detail with particular reference to
preferred embodiments, other embodiments can achieve the same
results. Variations and modifications of the present apparatus and
process of the invention will be obvious to those skilled in the
art and it is intended to cover in the appended claims all such
modifications and equivalence. The entire disclosures of all
references, applications, patents, and publications cited above,
and of the corresponding applications(s), are hereby incorporated
by reference.
* * * * *